2004 SUBARU FORESTER steering

RM-5
RECOMMENDED MATERIAL
Recommended Materials
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
5. COOLANT
Use genuine coolant to protect the engine.
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for ZXL200PG.
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil, front differential oil and rear differential oil
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
Grease Application point Recommended Item number Alternative
Supplementary lubricants  Oxygen sensor
 Bolts, etc.SUBARU CRC 004301003 —
RM-00004 (F)–22 –4 14 50 68 86 104 (C)–30 –20 –100
10 20 30 40
85W
75W-9080W90
32

RM-6
RECOMMENDED MATERIAL
Recommended Materials
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Grease MT main shaft FX 2200 clutch grease 000040901 —
Clutch master cylinder
push rodSlicolube G-40M 004404003 —
 Gear shift lever
 Select lever
 Clutch operating cyl-
inder
 Accelerator pedal
 Clutch pedal
 Brake pedal
 Hill holder
 Clutch bearing
 Clutch release lever
 Steering shaft bear-
ingSUNLIGHT2 003602010 —
Steering gearbox Valiant grease M-2 003608001 —
Disc brake Niglube RX-2 K0779GA102 —
 Drum brake
 Drum brake wheel
cylinderMolykote No. 7439 003602001 —
 Brake pad
Brake shoeMolykote AS-880N K0777YA010 —
Front axle AARi One luber C — —
Front axle AC HTBJ — —
Rear axle BJ Molylex No. 2 003601001 —
Rear axle EBJ NTG2218 — —
Rear axle DOJ VU-3A702 23223GA050 —
 Water pump
Door latch
Door strikerSlicolube G-30M 004404002 —
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Dow Automotive’s
Adhesive: Gurit-ESSEX
Betaseal 1502 or equivalent
Glass primer: Betawipe VP
04604 or Betawipe 5001
Paint surface primer: Betap-
rime 5402——
Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910
Inner rearview mirror
baseREPAIR KIT IN MR 65029FC000 — Grease Application point Recommended Item number Alternative

RM-7
RECOMMENDED MATERIAL
Recommended Materials
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
Seal material  Engine case
 Torque converter
clutch case
 Transmission case
(5MT)Three Bond 1215B 004403007 Dow Corning’s No. 7038
Transmission Three Bond 1217B K0877YA020 —
Rear differential Three Bond 1324 004403042 —
Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038
Weather strip Starcalking B-33A 000018901 Butyl Rubber sealant
Steering adjusting screw Three Bond 1102 004403006 —
SOHC camshaft cap Three Bond 1280B K0877YA018 —

PI-4
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
Checks with the Engine Running
Dynamic Test with the Vehicle Running
Checks after Dynamic Test
Step Check point
26. Test mode connectors Test mode connectors
27. Starting condition Start the engine and check that the engine starts smoothly.
28. Exhaust system Check that the exhaust noise is normal and no leaks are found.
29. Indicator light Check that all the indicator lights operate normally.
30. Clock Check that the clock operates normally.
31. Radio Check that the radio system operates normally.
32. Front accessory power supply socket Check that the front accessory power supply socket operates normally.
33. Lighting system Check that the lighting systems operate normally.
34. Window washer Check that the window washer system operates normally.
35. Wiper Check that the wiper system operates normally.
36. Power window operation check Check the power window for correct operations.
Step Check point
37. Brake test Check that the foot brake operates normally.
38. Parking brake Check that the parking brake operates normally.
39. AT shift control Check the AT shift patterns are correct.
40. Heater & ventilation Check that the heater & ventilation system operates normally.
41. Air conditioner Check that the air conditioner operates normally.
42. Speed control Check that the speed control operates normally.
Step Check point
43. ATF level Check that the ATF level is normal.
44. Power steering fluid level Check that the power steering fluid level is normal.
45. Fluid leak check Check for fluid/oil leaks.
46. Water leak check Spray the vehicle with water and check for water leaks.
47. Appearance check 2 (1) Remove the protective coating (wrap guard).(if any)
(2) Check the body paints for damage and smears.
(3) Check the plated parts for damage and rust.

PI-12
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
6) Set the AT select lever to each gear position
while checking that the demanded gear position is
correctly attained.
39.HEATER & VENTILATION
Operate the heater and ventilation system to check
for normal airflow outlet control, air inlet control, air-
flow capacity, and heating performance.
40.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
41.ATF LEVEL
Check that the ATF level is normal. If insufficient,
check that no leaks are found. Then add the neces-
sary amount of the specified ATF.
42.POWER STEERING FLUID LEVEL
Check that the power steering fluid level is normal.
If insufficient, check that no leaks are found. Then
add the necessary amount of the specified power
steering fluid.
43.FLUID LEAK CHECK
Check the entire areas of the vehicle for any trace
of coolant/oil/fluid leaks.
44.WATER LEAK TEST
Spray the vehicle with water and check that no wa-
ter enters the passenger compartment.
 Before performing the water leakage test, re-
move anything that may obstruct the operation or
which must be kept dry.
 Close all windows completely, and then close all
doors tightly. Close the hood before starting the
test.
 Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be ap-
prox. 20 — 252 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp
gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When di-
recting water on areas other than the floor portion
and wheel house, decrease the pressure. But the
force of water must be made strong occasionally by
pressing the end of the hose.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
from the vehicle.
Check the following areas:
 Front window and body framework mating por-
tion
 Door mating portions
 Glass mating portions
 Rear quarter window mating portions
 Rear window and body framework mating portion
 Around roof drips
(1) RHD model
(2) LHD model
Selector
Po si t io nGear Position
1st 2nd 3rd 4th
D OKOKOKOK
3 OKOKOK —
2OKOK——
1OK———
(A) Level gauge
(B) Check position when “HOT”
(C) Upper level
(D) Lower level
(E) Check position when “COLD”
PI-00112(1) (2)
P
R
N
D
3
2
1
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00070
(A)
(C)
(B)

PERIODIC MAINTENANCE SERVICE
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................7
4. Engine Oil Filter...........................................................................................9
5. Spark Plugs ...............................................................................................10
6. V-belt .........................................................................................................11
7. Timing Belt ................................................................................................13
8. Fuel Line ...................................................................................................17
9. Fuel Filter ..................................................................................................18
10. Air Cleaner Element ..................................................................................19
11. Cooling System .........................................................................................20
12. Engine Coolant..........................................................................................21
13. Clutch System ...........................................................................................23
14. Transmission Gear Oil ..............................................................................24
15. Hill-holder System .....................................................................................25
16. ATF ...........................................................................................................26
17. Front & Rear Differential Oil ......................................................................28
18. Brake Line .................................................................................................30
19. Brake Fluid ................................................................................................32
20. Disc Brake Pads and Discs .......................................................................33
21. Brake Linings and Drums ..........................................................................34
22. Suspension ...............................................................................................36
23. Wheel Bearing...........................................................................................38
24. Axle Boots & Joints ...................................................................................39
25. Tire Rotation..............................................................................................40
26. Steering System (Power Steering) ............................................................41

PM-3
PERIODIC MAINTENANCE SERVICE
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. FOR EUROPE AREA
For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring
to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 120,000 km (75,000 miles) or 96 months.
Symbols used:
R: Replace
I: Inspection
(I): Recommended service for safe vehicle operation.
N
OTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.Maintenance interval
[Number of months or km (miles), whichever occurs first]
Month 1224364860728496
Remarks ×1,000 km 1.6 5 15 30 45 60 75 90 105 120
×1,000 miles 1 3 9 19 28 38 47 56 66 75
1Engine oil RRRRRRRR
2Engine oil filter RRRRRRRR
3 Spark plug For Turbo R
Others RRRR
4Drive belt(s) IIIIIIII
5Camshaft drive belt RRRR
6Fuel line IIII
7 Fuel filter R R
8 Air cleaner element I R I R I R I R
9Cooling system IIII
10Coolant RRRR
11Clutch system IIII
12Hill-holder system IIII
13 Transmission oil I R I R
14 ATF I R I R
15 Front & rear differential I R I R
16Brake line IIII
17Brake fluid RRRR
18Disk brake pads & discs IIIIIIII
19Brake linings & drums IIII
20Parking brake IIII
21Suspension IIII
22 Wheel bearing(I)
23Axle boot & joint IIIIIIII
24Steering system IIII

PM-4
PERIODIC MAINTENANCE SERVICE
Schedule
2. EXCEPT FOR EUROPE AREA
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 50,000 km (30,000 miles) or 48 months.
For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 100,000 km (60,000 miles) or 48 months.
Symbols used:
R: Replace
I: Inspection
(I): Recommended service for safe vehicle operation.
N
OTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48
Remarks ×1,000 km 5 12.5 25 37.5 50
×1,000 miles 3 7.5 15 22.5 30
1 Engine oil R R R R
2 Engine oil filter R R R R
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48
Remarks ×1,000 km 1.6 25 50 75 100
×1,000 miles 1 15 30 45 60
3 Spark plugs For Turbo R
Others R R R R
4Drive belt(s) IIII
5 Camshaft drive belt R
6 Fuel line I I
7 Fuel filter R R
8 Air cleaner element I R I R
9 Cooling system I I
10 Coolant R R
11 Clutch system I I I I I
12 Hill-holder system I I I I I
13 Transmission oil R R
14 ATF R R
15 Front & rear differential oil R R
16 Brake line I I
17 Brake fluid R R
18 Disc brake pads & discs I I I I
19 Brake linings and drums I I
20 Parking brake I I I I
21 Suspension I I I I
22 Wheel bearing (I)
23 Axle boots & joints I I I I
24 Steering system (Power steering) I I I I